5. Locate and drill out all factory welds.
Important: Note the number and location of welds for
installation of the front wheelhouse.
6. Remove the front wheelhouse from the vehicle.
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes as necessary
in the locations noted from the original assembly.
2. Prepare the mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
4. Position the front wheelhouse in the vehicle using
3-dimensional measuring equipment. Clamp the
wheelhouse in place.
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2003 Saturn Ion
3-33
2003 Saturn Ion
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